ASSEMBLY INSTRUCTIONS SPEEDRAIL SyStEm - …€¦ · · 2017-06-20¬ The assembly instructions of the module manufacturer are to be adhered to. ... Self-tapping screw 6 x 36 Material:

ASSEMBLY INSTRUCTIONSSPEEDRAIL SyStEm

GB

Mounting systems for solar technology

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TABLE OF CONTENTS

THE COMPANY

SAFETY REGULATIONS

MATERIALS REQUIRED

TOOLS REQUIRED

ASSEMBLY

Table of conTenTs

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PaRTneR WITH a sYsTeM

TesTeD QUalITY – foUR ceRTIfIcaTIons

With sophisticated, fully developed product ideas and obvious customer-orientation, K2 Systems is your friendly partner in the field of mounting systems for solar technology.International customers appreciate the tried and tested designs for use on roofs and in outdoor and individual solutions.

Mounting systems from K2 Systems impress with their attractive design and many well thought-out details. High grade materials and quality workmanship guarantee outstanding functionality and durability.

Our products consist of few yet perfectly matching components - this reduces the amount of material used, simplifies assembly while saving time and money.

As an energetic, experienced company, and in keeping with the times, we benefit from cooperation as partners in order to ensure the dynamic development of our company. The experiences from the personal dialogue with our customers forms the basis for permanent optimisation of our range of pro-ducts.The team of K2 Systems looks forward to a successful cooperation with you.

K2 Systems stands for secure connection, highest quality and precision. Our customers and business partners have already known that for a long time. And three independent institutes have tested, confirmed and certified our capabilities and components.

3 | 18The Company

GeneRal safeTY InsTRUcTIons

Please be aware that our General Assembly Regulations must be adhered to. They can be viewed under www.k2-systems.de/english/downloads/customer-area.html. If you don’t already have them, you can obtain access data for our customer area on request.

In general, the following applies:

¬ Systems may only be installed and put into use by people who can ensure the proper carrying-out of the work due to their technical suitability (e.g. training or occupation) and/or experience.

¬ Before assembly, it must be checked that the product meets the local static requirements. For roof systems, the load-bearing capacity of the roof has to be checked in principle.

¬ National and local building regulations, standards and environmental regulations are always to be adhered to.

¬ Work safety and accident prevention regulations and corresponding standards and regulations of occupational associations are to be adhered to! In particular, it is to be ensured that: - Safety clothing is worn (especially safety helmets, work shoes and gloves). - For work on roofs, the regulations for working on roofs are to be adhered to (e.g. use of anti-fall guards, scaffolding with arrestor equipment from an eaves height of 3m etc.) - Presence of two people is vital for the entire course of the assembly, so that swift help can be ensured in the case of an accident.

¬ K2 mounting systems are constantly being developed further. Because of this, assembly procedures can change. Therefore, before assembly, always check that the assembly instructions are up-to-date under www.k2-systems.de/english/downloads/customer-area.html. We can also send you the latest version on request.

¬ The assembly instructions of the module manufacturer are to be adhered to.

¬ Earthing must be ensured, use lightning arrestor clamp if necessary.

¬ During the entire assembly time it is to be ensured that at least one copy of the assembly instructions is available on site.

¬ In the event of non-adherence to our General Safety Instructions and if competitor’s parts are built in or attached, K2 Systems GmbH reserves the right to refuse liability.

¬ With disregarding our general installation and assembly instructions and not using all system components and assemblies according to these instructions as well when components are used, which were not obtained from us, K2 Systems is not liable for any resulting defects and damages. Warranty is excluded in such cases.

¬ If all safety instructions are adhered to and the system is correctly installed, there is a product warranty entitlement of 12 years! Please read out Terms and Conditions of Warranty which can be viewed under www.k2-systems.de/deutsch/downloads. We can also send them to you on request.

¬ The dismantling of the system takes place according to the assembly steps, in reverse order.

¬ K2 components made of stainless steels are available in different corrosion resistance classes. In every case, the expected corrosion exposure of each structure or component must be checked.

4 | 18Safety Regulations

essenTIal: THe MaTeRIals ReQUIReD

All system components listed in the following are essential for assembling the K2 Systems SpeedRail system. The piece quantities are calculated on the basis of the respective requirements. The listed item numbers facilitate the comparison of items.

SpeedRail 22

Material: aluminium

Alternative: SpeedRail 36

Material: aluminium

SpeedClip

Material: fibre-glass reinforced plastic, EPDM

Self-tapping screw 6 x 36

Material: stainless steel, jointing: EPDM, wrench size: 8 mm

Alternative: Self-tapping moulded screw 6 x 38Material: stainless steel, EPDM, SW 8

M K2 slot nut with clip

Material: stainless steel, fibre-glass reinforced plastic

SpeedConnectorMaterial: Aluminium

Self-Drilling Countersunk Screw 4,8 x 16Material: stainless steel, drive: TX 25

SpeedConnector Set

Set consists of:

| item number system-specific


| 1005193

| 1001164

| 1001643

| 1003571

| 1001622

5 | 18Materials Required

SpeedLock Set

Set consists of:

SpeedLockMaterial: Aluminium

DIN 7991 hexagon socket countersunk head screw M8 x 20Material: stainless steel

M K2 slot nut with clipMaterial: stainless steel, plastic

| For SpeedRail 22 1003558 For SpeedRail 36 1003560

Allen Bolt DIN 912 M8

Material: stainless steel, SW: 18 mm

Lock washer DIN EN 10151

Material: stainless steel

| 1000473

K2 Module End Clamp Set Standard

Material: Aluminium

K2 Module Middle Clamp Set Standard

Material: Aluminium

Alternative: module end clamp XS




6 | 18Materials Required

aT a Glance: oVeRVIeW of THe Tools

K2 Systems mounting systems are designed to ensure effortless assembly. Only the tools that are required are not included in the scope of supply. Here we have listed them together for ease of reference.

Measuring tape

Cordless Screwdriver

With attachment for width across flats 8, and TX 25

Torque wrench

With attachment for HW5 and HW 6

Chalk line

7 | 18Tools Required

In order to ensure safe and correct assembly of the system, please first read through all of the steps. For each step, the materials required are listed. If you have problems or questions relating to the system, please contact our

SERvIcE-HotLInE on tHE numBER: +49 (0) 7152-3560-0

Generel Instruction:

¬ Earthing must be ensured (use lightning arrestor clamp if necessary).¬ The General Mounting Regulations absolutely must be adhered to. You will find these instructions under: www.k2-systems.com/en/downloads/product-information.html If you don’t already have them, you can obtain access data for our customer area on request.¬ If the troughed sheet is to be fastened with calottes, please never bolt the SpeedClips to the calottes! Instead of this, mount all SpeedClips staggered in this sequence on the troughed sheet.¬ the modules may never be fixed over the thermal expansion joint.¬ The product is petty-patent-protected and patent pending.

mount SPEEDcLIPS

Align SpeedClips horizontally with each other using a chalk line, and mark the position of the rail on the roof. Mount each SpeedRail onto the high bead. The K2 logo here points in the direction of the roof ridge. Distance from the edge: each a quarter of the rail length (with max. 6.10 m: approx. 1.5 m). The SpeedClips themselves are each fastened with two self-tapping hexagonal screws 6 x 36 mm with EPDM seal washers.

¬ No pre-drilling! – Except in the case of overlapping sheets, to avoid spaces.¬ Thickness of steel troughed sheet: min. 0.5 mm (assuming 360 N/mm2)¬ Thickness of aluminium troughed sheet: min. 0.8 mm (assuming 195 N/mm2)¬ Spacing dimension between axes and top edge SpeedClip: 55 mm¬ Tightening torque based on flush fit.

Materials required: SpeedClip, tapping screws with sealing washer See page 17 for instructions for special space-saving assembly.

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8 | 18Assembly SpeedRail System

sPeeDRaIl-asseMblY: sTeP bY sTeP

9 | 18Assembly SpeedRail system

PLAcE SPEEDRAIL

Lay SpeedRail onto the supporting area of the SpeedClips…

… and push into the lower groove.

Guide the SpeedRail diagonally into the upper groove of the first two SpeedClips fixed on the roof and push upward until they can go no further.

Materials required: SpeedRail

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PLAn In tHERmAL EXPAnSIon

The SpeedRail must always be built in the clamping range approved by the module manufacturer. However, due to thermal expansion, we recommend that the rows be interrupted after 6.10 m; they must be interrupted after a maximum of 8.40 m (2 x 4.20 m). The minimum spacing for thermal cut is 3 - 5 cm between two rails.the modules may never be fixed over the thermal expansion joint.

Materials required: SpeedRail

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…press onto the rail…

…push SpeedClip downwards along the rail into the top groove of the SpeedClip…

…and then push into the correct position on the top bead.

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FIX SPEEDRAIL In PLAcEWItH ADDItIonAL SPEEDcLIPS

In the low beads, push further SpeedClips onto the rail…

Materials required: SpeedClip


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FAStEn SPEEDcLIPS

Fasten each SpeedClip with two self tapping screws 6 x 36 mm. The number of additional clips that are required depends on the wind and snow loads and is stated in the issuing of the order.screw down the self-tapping screws to flush fit.

Materials required: SpeedClip, self tapping screws with sealing washer

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ADHERE to cLIP SEQuEncEAnD SPAcInG

Insert every fourth clip with the K2 logo downward in order to prevent shifting in the direction of the roof edge.

Distances between two clips:• Roof edge area: max. 40 cm• Roof centre: max. 75 cm; when mounting in cross-bracing: max. 50 cm

For reasons of seating stress and tightness, never build two SpeedClips into a top bead! For rail joints directly on a top bead: always fasten SpeedClips to the respective closest top bead of the rails.

Important! At the end of each rail, a Speedclip must be fastened to the last top bead! the cantilever of the rail must be no more than 25 cm.

Materials required: SpeedClip, self tapping screws with sealing washer

Assembly SpeedRail system 13 | 18

LAyInG “FLuSH”

The roof panel must under no circumstances be drilled through! Therefore never drill in the area of the top bead! One must drill so as to prevent a collision with slot nuts later inserted.

Between two rails joined “flush” against each other, always use a SpeedConnector: insert this into the rails and bolt to the rail itself with 2 countersunk self-tapping screws 4.8 x 16 in the area of the bottom beads. Tightening torque moment max. 4 Nm. A row of joined rails may be no longer than 8.40 m. The minimum rail length must not be shorter than 1.00 m.

Materials required: SpeedConnector, countersunk drilling screw 4.8 x 16

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ASSEmBLy SPEEDLock

The SpeedLocks must always be mounted in the middle of the rail. The middle point of joined rails is the middle of the total length. First insert an M K2 slot nut level with a Speed-Clip and turn it clockwise by 90°. Screw the SpeedLock over the SpeedClip with the M K2 using an M8 x 20 countersunk head screw. Tightening torque 14 Nm. The SpeedClip fas-tens the SpeedLock and therefore the row of rails. Materials required: M K2, SpeedLock, hexagon socket coun-tersunk head screw M8 x 20

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ImPoRtAnt InFoRmAtIon

• Rows of rails up to a length of 6.10 m will require one SpeedLock and rows of rails up to a length of 8.40 m require two SpeedLocks. • SpeedLock 22 should be used for SpeedRail 22 and SpeedLock 36 for SpeedRail 36.• these assembly instructions must also be followed for space-saving assembly (see page 17) and Addon assembly (see page 18).

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FAStEn moDuLES

Each module at the end of a row is to be fastened with end clamps and Allen bolts DIN 912 M8 and slot nuts.

First of all, insert the slot nut M K2 in the SpeedRail and turn 90° clockwise. If the end and middle clamps are supplied as a set, please fix the whole set in the rail. Fasten the solar modules onto the rails according to the manufacturer’s information.Tightening torque moment 14 Nm.

Materials required: M K2 slot nuts, end clamps, Allen bolt M8, locking washer S8

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AttAcH moDuLE GAPS

Attaching with Standard middle clamp

Use two standard middle clamps between two modules, which also need to be screwed with DIN 912 M8 in the slot nuts. Pay attention to the mounting instructions by module manufacturer! Tightening torque 14 Nm.

Required materials: Middle Clamp Set

Fixieren mit XS modulmittelklemme

Zwischen zwei Modulen jeweils zwei XS Modulmittelklem-men verwenden, welche ebenfalls mit Schrauben DIN 912 M8 in den Einlegemuttern zu verschrauben sind.Bei der XS Modulmittelklemme werden längere Schrauben benötigt als bei der Modulmittelklemme Standard. Anzugsdrehmoment 14 Nm

Required materials: Middle Clamp Set XS

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ImPoRtAnt InStRuctIonS FoR ASSEmBLy

¬ For the SpeedRail 36: module cables can be laid within the rail, but the plugs must not lie in the rails.¬ When laying frameless modules vertically, always build in a stopper to prevent sliding-off for each module.¬ Slot nuts at butt joints of the rails must be avoided!¬ Never mount middle or end clamps directly onto the rail joint or rail end! (Distance: min. 20 mm from end clamp)¬ The modules may never be fixed over the thermal expansion joint.

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SPAcE-SAvInG ASSEmBLy

RAIL PRoJEctIon

You can offset every second row of rails to save space when assembling the SpeedRail. The space between the rails is the space required for mounting the SpeedClips. The next rail is laid at the same height as the first. This assembly method reduces the distance between the modules at the end of the rail to 40 mm. Module edges should be aligned. The total length of a row of rails may not exceed 8.40 m.

Module installation can be optimised using the K2 XS middle clamp (13 mm between modules). Important: you will need longer screws.

Space-saving assembly is particularly suitable for integrated roof solutions on trapezoidal sheet metal roofs in France.

How far the rail projects depends on the width of the mo-dules. It must be at least 20 mm from the end clamp. Please note that the clearance between two clips on a seam have to be at least 10 mm.

ALtERnAtIvE SyStEm ASSEmBLy


SPEEDRAIL WItH ADDon ASSEmBLy

The total rail length for modules mounted horizontally in a grid formation using the K2 AddOn may not exceed 8.40 m. The thermal cut must be at least 3 - 5 cm. Modules are mounted using the K2 AddOn, the M K2 slot nut and end and middle clamp and the M8 Allen bolt.If this assembly method is to be used, the roof must be correctly measured out and you must work with ext-reme precision.

Important: modules may not be clamped over the rail joint.you must follow the k2 Addon assembly instructions.

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tHAnk you vERy mucH FoR DEcIDInG to PuRcHASE A k2 mountInG SyStEm.

Systems from K2 Systems are fast and simple to install. We hope these instructions have helped you in this. Please contact us if you have any questions or suggestions for improvements. We are looking forward to receive your call on our

SERvIcE-HotLInE +49 (0) 7152-3560-0

Our General Terms of Business apply. Please refer to http://www.k2-systems.com/en/gsc.html. German Law shall apply excluding the UN Convention on CISG. Place of venue is Stuttgart.

Ready!

Montageanleitung speedRail | Gb9 | 1013 | subject to change.Product illustrations are exemplary illustrations and may differ from the original.

Mounting systems for solar technology

Everest Solar Systems, LLC3809 Ocean Ranch Blvd.Suite 111Oceanside, CA 92056USATel +1.760.301.5300info@everest-solarsystems.comwww.everest-solarsystems.com

K2 Systems SARL19 Avenue du Pré de Challes Parc des Glaisins74940 Annecy le VieuxFranceTel. +33 (0) 4 50 51 22 53Fax +33 (0) 4 50 51 16 [email protected]

K2 Systems GmbHRiedwiesenstraße 13 - 1771229 LeonbergGermanyTel +49 (0) 7152 - 3560 - 0Fax +49 (0) 7152 - 3560 - [email protected]

K2 Systems s.r.l.Via Madonna dello Schioppo 67Secondo Piano Int. 17-1947521 Cesena (FC)ItalyTel. +39 0547 63 20 80Fax +39 0547 63 50 [email protected] www.k2-systems.it

K2 Solar Mounting Solutions Ltd.Unit 46 Easter ParkBenyon RoadAldermaston, Berkshire RG 7 2PQUnited KingdomTel. +44 (0) 1189 [email protected]

SERVICE-HOTLINE+49 (0)7152 3560-0

Documents

ASSEMBLY INSTRUCTIONS SPEEDRAIL SyStEm - …€¦ · · 2017-06-20¬ The assembly instructions of the module manufacturer are to be adhered to. ... Self-tapping screw 6 x 36 Material: